Extruded honeycomb catalyst

ABSTRACT

An extruded honeycomb catalyst for nitrogen oxide reduction according to the selective catalytic reduction (SCR) method in exhaust gases from motor vehicles includes an extruded active carrier in honeycomb form having a first SCR catalytically active component and with a plurality of channels through which the exhaust gas flows during operation, and a washcoat coating having a second SCR catalytically active component being applied to the extruded body, wherein the first SCR catalytically active component and the second SCR catalytically active component are each independently one of:
         (i) vanadium catalyst with vanadium as catalytically active component;   (ii) mixed-oxide catalyst with one or more oxides, in particular those of transition metals or lanthanides as catalytically active component; and   (iii) an Fe- or a Cu-zeolite catalyst.

The invention concerns an extruded honeycomb catalyst, in particular forexhaust gas cleaning, especially in the domain of motor vehicles, whereit is used in particular for nitrogen oxide reduction according to theselective catalytic reduction (SCR) method, i.e. the reduction of oxidesof nitrogen using a nitrogenous reductant. The invention also concerns aset of such variously embodied honeycomb catalysts and a method forproducing honeycomb catalysts.

Extruded honeycomb catalysts are one-piece, monolithic objects, whichhave a plurality of channels through which the exhaust gas flows duringoperation. These channels have an opening width of just a fewmillimetres. The webs delimiting the individual channels also typicallyhave a width of just 300 μm. In extruded honeycomb catalysts, in whichthe solid material is catalytically active, a high proportion by volumeof the solid body consists of catalytically active components. Theresult of this is that any modifications of the catalytic components,for example to make adaptations to different requirements and in generalto pursue refinements, have a critical effect on extrudability.Altogether, this makes the development period for a new extrudedhoneycomb catalyst, in which the solid material is catalytically active,expensive.

WO 2010/099395 A1 discloses extruded honeycomb catalyst bodies andmethods of manufacturing them. The catalyst body induces a first oxideselected from the group consisting of tungsten oxides, vanadium oxidesand combinations thereof, a second oxide selected from the groupconsisting of cerium oxides, lanthanum oxides, zirconium oxides andcombinations thereof and a zeolite. In one embodiment, an extrudedzeolite core is coated with a layer of a mixture of a cerium oxide, azirconium oxide and a tungsten oxide.

On that basis, the invention is based on the problem of specifying ahoneycomb catalyst which can be adapted to new requirements with lowdevelopment costs.

The problem is solved according to the invention by claim 1. Accordingto this claim, provision is made that the honeycomb catalyst as a wholeis formed from an extruded, active carrier in honeycomb form, which hasat least one catalytically active component and on which in addition acatalytically active coating, in particular a washcoat coating, isapplied, which thus likewise has at least one catalytic component.

The problem is further solved according to the invention by a set ofhoneycomb catalysts which differ in terms of their functionality, butwhich each have an identical carrier, and by a method for producinghoneycomb catalysts of this type.

This embodiment is based on the idea of developing and providing acarrier which can be used universally for several domains of applicationand making specific adaptations to the respective requirements via thespecial washcoat coating. The particular advantage is to be seen in thefact that a different extrusion mass does not have to be developed andprovided for different honeycomb catalysts. At the same time, because ofthe option of different combinations between the active carrier and thelikewise catalytically active coatings, the entire catalytic activitycan be adapted and designed as appropriate. In principle, this providesthe option, firstly, of developing the catalyst with a view to atechnically optimised functionality or alternatively with a view to acatalyst optimised in terms of cost. In order to achieve the latter, inparticular, provision is made that the proportion of the catalyticallyactive component in the carrier is reduced by comparison withconventional catalytically active solid extrudates.

Also it is possible to improve SCR activity of a catalyst which isotherwise sensitive to gas composition, e.g. ratio of NO₂:NO (seeFe/ZSM-5 (MFI) SCR in EP 1147801).

Preferred embodiments can be derived from the sub-claims.

The carrier and the washcoat coating are both formed as SCR catalysts.In particular, there are three different known types of catalysts withapplication in the present invention:

-   -   a catalyst referred to below as a vanadium catalyst, with        vanadium as catalytically active component. This usually        contains, as main components, vanadium oxide, titanium oxide and        tungsten oxide. In conventional catalytically active solid        extrudates the proportion by volume of these catalytically        active main components is about 75 to 85 vol %.    -   The second type of catalyst is a mixed oxide catalyst with one        or more oxides or lanthanides as catalytically active        components. Typically-used metal oxides are, for example, cerium        oxide, zirconium oxide or tungsten oxide, which in conventional        catalysts have a proportion by volume of about 75 to 85%. Mixed        oxide catalysts of this type are usually free from zeolites and        also free from vanadium.    -   As third SCR catalyst type, metal-zeolite catalysts are known        with a metal zeolite as catalytically active component. In        particular, this is an iron-zeolite or copper-zeolite. In a        zeolite catalyst of this type, the proportion by volume of these        active components lies in the range of about 60 to 70% in        conventional solid extrudates.

The rest of the solid extrudate is formed by catalytically inactivecomponents, such as binders, fillers if necessary to increase strengthand optionally a plasticiser for support during extrusion.

Advantageously, the proportion by volume of the active components in thecarrier is lower than in conventional solid extrudate catalysts, inwhich the proportions lie in the range of the upper limits stated above.All in all, the proportion by volume in the carrier can be adjusted from10 vol. % to the upper limit stated above. In particular, however, arange under 50 vol. % or a range between 10 and 60 or 10 and 40% is set.In some variant embodiments, therefore, the greater proportion by volumeof the catalyst is formed by inactive components.

In the variant embodiments with the reduced catalytically activeproportion, this is preferably replaced by components which are neutralwith respect to the extrusion process. This means that these are easilyextrudable masses and/or materials. These include, in particular, clays(this means sheet silicates with a grain diameter of less than 2 μm),aluminium oxide or else kaolin.

The honeycomb catalyst according to the invention, in particular thesecond SCR catalyst washcoat coating, is free from noble metals, atleast in the front area. In one preferred embodiment, a noble metalcoating is applied, especially as a washcoat, onto a rear—viewed in thedirection of flow of the exhaust gas during operation—area. This servesto prevent ammonia slip. The rear area therefore forms what is known asan ASC catalyst (ammonia slip catalyst).

Advantageously this noble metal coating is thereby embedded in the formof a sandwich between the carrier and a washcoat coating extending overthe entire length, which is in particular embodied as an SCR catalyst.That is, the noble metal-containing washcoat is applied as a layerdirectly onto the carrier and the second SCR catalyst washcoat layer isapplied over an entire length of the extruded active carrier, includingthe noble metal-containing washcoat. This arrangement has the benefitthat ammonia which slips past the upstream zone of the first and secondSCR catalysts can be oxidised to NO_(x) on the lower, noble metal layerand this NO_(x) then passes through the second SCR catalyst layer toexit the catalyst structure and contacts in-coming ammonia, whereby theNO_(x) is reduced to N₂ on the second SCR catalyst.

For all variant embodiments, the washcoat coating has a relatively highporosity, so that the exhaust gas to be cleaned also comes into contactwith the catalytically active carrier.

In order to achieve a good catalytic activity, the carrier also has ahigh porosity. Both the carrier and the washcoat coating typically havea large BET surface area in the range of about 40 to 80 m²/g.

The layer thickness of the washcoat coating preferably lies in the rangeof 30 to 100 μm, in particular in the range of about 40 to 60 μm.Advantageously, only a single washcoat coating is applied to thecarrier. Because the carrier is also active, a multi-layered washcoatcoating is not necessary and preferably not provided. It is, however,possible.

In particular, in the case of catalytically active solid extrudates witha reduced proportion of active components in the solid extrudate, theweb width of the webs of the honeycomb structure can be reduced. Inconventional extruded honeycomb catalysts made from a catalyticallyactive solid extrudate, the web widths are in the range of about 300 μm.This is preferably reduced to a range of about 150 to 220 μm, inparticular to a range of about 180 μm.

Using the concept of an active washcoat coating on a carrier, differentactive honeycomb catalysts can be designed according to requirements tomeet different needs.

These different combinations take into account the various advantagesand disadvantages of the individual catalysts, which are preferablycombined in such a way that their advantages are increased and theirdisadvantages are reduced. So the individual catalysts differ firstlyfrom an economic viewpoint with respect to their price. Here, forexample, the copper-zeolite catalyst is the most expensive, while thevanadium catalyst is the cheapest. With respect to their technicalcharacteristics, NOx-activity across the temperature range is especiallyimportant, i.e. the capacity for NOx-reduction at both low and hightemperatures. Furthermore, sulphur tolerance and in particular NO₂tolerance are of particular importance. Finally, the temperaturestability of different materials is also relevant.

Depending on the intended use, the following preferred combinationpossibilities are suitable:

-   -   a) Embodiment of the carrier as a mixed oxide catalyst with a        washcoat coating, which can be either an Fe- or a Cu-zeolite        catalyst. The advantage of the mixed oxide catalyst here lies in        its low storage capacity, in particular ammonia storage        capacity. Ammonia is regularly used in the SCR method as a        typical reducing agent. This enables simple dosing as a function        of the current demand. The mixed oxide catalyst displays        weaknesses in the higher temperature range, which are equalised        by the washcoat coating. Conversely, in the lower temperature        range it is better by comparison with the Fe-zeolites, so that,        overall, improved activity is achieved over the entire        temperature range.    -   b) A washcoat coating made from a vanadium catalyst is applied        to a carrier made from a mixed oxide catalyst. The advantage of        the vanadium catalyst consists in its good sulphur tolerance,        which is, conversely, a weakness of the mixed oxide catalyst.        Conversely, the mixed oxide catalyst has higher activity at        lower temperatures. A further advantage of the mixed oxide        catalyst can be seen in its good NO₂ tolerance.    -   c) A washcoat made from a copper-zeolite is applied to a carrier        made from an Fe-zeolite. The very good activity in the lower        temperature range of the copper zeolite is supplemented by the        good sulphur tolerance of the iron zeolite. Also, a combination        of this type is especially tolerant to NO₂, since iron has        especially good activity when there are medium and high NO₂        levels, while copper has a very good activity when there are low        NO₂ levels in the exhaust gas.    -   d) An Fe-zeolite is applied to a Cu-zeolite as washcoat. Here,        the same advantages apply as in the aforementioned combination.    -   e) A vanadium catalyst as washcoat is applied to an Fe-zeolite        as carrier. This combination has improved sulphur resistance and        a high NO₂ tolerance, since the iron-zeolite catalyst has high        activity when there are high NO₂ levels in the exhaust gas,        contrary to the vanadium catalyst.    -   f) The combination of identical catalysts, for example        Fe-zeolite catalyst with Fe-zeolite catalyst. This increases        catalytic activity overall.    -   g) An Fe-zeolite catalyst is applied to a carrier made from a        vanadium catalyst. This achieves a very good activity over a        wide range of NO₂/NOx-ratios.

The concept described here, namely the provision of an active carrier incombination with an active washcoat coating, therefore also findsexpression in the method according to the invention. To producehoneycomb catalysts with different characteristics, therefore, a carriertype is supplied and stored which is then provided, depending on thedomain of application, with different washcoat coatings.

According to a further aspect, there is provided an exhaust system for avehicular lean burn internal combustion engine comprising an extrudedhoneycomb catalyst according to the invention disposed in a flow conduitthereof.

In one embodiment, the exhaust system comprises means for injecting anitrogenous reductant or a precursor thereof into the exhaust gasupstream of the extruded honeycomb catalyst.

According to a further aspect according to the present invention, thereis provided a lean burn internal combustion engine comprising an exhaustsystem according to the invention comprising a catalyst for generatingNH₃ in situ in exhaust gas upstream of the extruded honeycomb catalystand control means for changing an exhaust gas composition to acomposition which promotes in situ NH₃ on the catalyst for generatingNH₃ in situ.

In one embodiment, the catalyst for generating NH₃ in situ in exhaustgas upstream of the extruded honeycomb catalyst is a diesel oxidationcatalyst or a NO_(x) absorber catalyst and in particular comprises aplatinum group metal and preferably also a lanthanide element,preferably cerium optionally in combination with one or more stabiliserssuch as zirconia and/or a rare earth element.

According to a further aspect, there is provided a vehicle comprising anexhaust system according to the invention or a lean burn internalcombustion engine according to the invention.

In order that the present invention may be more fully understood, thefollowing Examples are provided by way of illustration only and withreference to the accompanying drawings, wherein:

FIG. 1 is a graph showing the NO_(x) conversion activity at varioustemperatures for an extruded honeycomb catalyst according to the presentinvention comprising an extruded active carrier comprising aV₂O₅/WO₃/TiO₂ or Fe-ZSM-5 (MFI) zeolite first SCR catalyst washcoatedwith a WO₃/CeO₂—ZrO₂ second SCR catalyst compared with the second SCRcatalyst coated on an inert cordierite honeycomb and the extruded activecarriers without the second SCR catalyst coating;

FIG. 2 is a graph showing the NO_(x) conversion activity at varioustemperatures for an extruded honeycomb catalyst according to the presentinvention comprising an extruded active carrier comprising a Fe-ZSM-5(MFI) zeolite first SCR catalyst washcoated with a Cu-SAPO-34 (CHA)second SCR catalyst compared with the second SCR catalyst coated on aninert cordierite honeycomb and the extruded active carrier without thesecond SCR catalyst coating;

FIG. 3 is a graph showing the NO_(x) conversion activity at varioustemperatures for an extruded honeycomb catalyst according to the presentinvention comprising an extruded active carrier comprising a Fe-Betazeolite first SCR catalyst washcoated with a Cu-SSZ-13 (CHA) second SCRcatalyst at two different washcoat loadings compared with the sameloadings of the second SCR catalyst coaxed on an inert cordieritehoneycomb and the extruded active carrier without the second SCRcatalyst coating; and

FIG. 4 is a graph showing the NO_(x) conversion activity at varioustemperatures for an extruded honeycomb catalyst according to the presentinvention comprising an extruded active carrier comprising aV₂O₅/WO₃/TiO₂ first SCR catalyst washcoated with a Cu-SSZ-13 (CHA)second SCR catalyst at two different washcoat loadings compared with thesame loadings of the second SCR catalyst coated on an inert cordieritehoneycomb and the extruded active carrier without the second SCRcatalyst coating.

EXAMPLES Example 1 Preparation of Extruded Active Carrier in HoneycombForm Comprising First SCR Catalyst Example 1A Extruded Active CarrierContaining Fe-Beta Zeolite

Powdered commercially available Beta zeolite in hydrogen form is mixedwith iron oxide (Fe₂O₃), glass fibres, Kaolin, powdered syntheticboehmite and the plasticisers polyethylene oxide (2.25 wt. %) and oleicacid (1.62 wt. %) (both based on 100% of the total inorganic solidscontent) and is processed in an aqueous solution with a pH-value of 5-6into a shapeable and flowable slip. When the mixture is wellplasticised, cellulose is added at 2.25 wt % based on 100% of the totalinorganic solids content. The quantitative proportions of the startingmaterials are selected in such a way that the active material of thefinished solid catalyst body contains 70.34% by weight of zeolite, ironand iron compounds; 2.76% by weight of the Kaolin; 15.94% by weight ofγ-Al₂O₃; and 4.84% by weight of glass fibers. The shapeable mixture isextruded into a flow-through honeycomb catalyst body, i.e. withcontinuous channels and with a circular cross-section exhibiting a celldensity of 400 cpsi (cells per square inch). Subsequently, the catalystbody is freeze dried for 1 hour at 2 mbar according to the methoddescribed in WO 2009/080155 (the entire contents of which isincorporated herein by reference) and calcined at a temperature of 580°C. to form a solid catalyst body. It is found that by using the methoddescribed that at least some of the iron introduced into the mixturebecomes ion-exchanged with the zeolite.

Example 1B Extruded Active Carrier Containing V₂O₅/WO₃/TiO₂

Powdered commercially available tungsten-containing TiO₂ at 10 wt. %tungsten is mixed with glass fibres, Kaolin, a low alkaline clay fillerand powdered synthetic boehmite Ammonium metavanadate: 1.88 wt. %;2-Aminoethanol: 1.5 litres; Lactic acid 90%: 0.48 wt %; Ammonia 25%:8.97 wt % and the plastieisers polyethylene oxide (0.86 wt. %) and oleicacid (0.14 wt. %) (all based on 100% of the total inorganic solidscontent) and is processed in an aqueous solution with a pH-value of 5-6into a shapeable and flowable slip. When the mixture is wellplasticised, cellulose is added at 0.86 wt % based on 100% of the totalinorganic solids content. The quantitative proportions of the startingmaterials are selected in such a way that the active material of thefinished solid catalyst body contains approximately 72 wt %V₂O₅/WO₃/TiO₂; silica 1.20 wt %; Kaolin 2.85 wt %; clay 2.85 wt. %; andglass fibres 6.93 wt. %. The shapeable mixture is extruded into aflow-through honeycomb catalyst body, i.e. with continuous channels andwith a circular cross-section exhibiting a cell density of 400 epsi(ceils per square inch). Subsequently, the catalyst body is freeze driedfor 1 hour at 2 mbar according to the method described in WO 2009/080155(the entire contents of which is incorporated herein by reference) andcalcined at a temperature of 580° C. to form a solid catalyst body.

Example 1C Extruded Active Carrier Containing Fe-ZSM-5 (MFI) Zeolite

An ion-exchanged, synthetic ZSM-5 zeolite, the active material of whichcontains 5% by weight of iron, is selected as zeolite. The powderedZSM-5 zeolite is mixed with glass fibers and powdered synthetic boehmiteand is processed in an acetous aqueous solution with a pH-value of 3.5into a shapeable and flowable slip by admixture of cellulose, and oleicacid and polyethylene glycol plasticizers. The quantitative proportionsof the starting materials are selected in such a way that the activematerial of the finished solid catalyst body contains 75% by weight ofzeolite containing the iron and iron compounds; 11.8% by weight ofγ-Al₂O₃ and 8% by weight of glass fibers. The shapeable mixture isextruded into a honeycomb catalyst body with continuous channels andwith a round cross-section exhibiting a cell density of 400 cpsi (cellsper square inch). Subsequently, the catalyst body is dried at atemperature of 90° C. and calcined to form a solid catalyst body at atemperature of 600° C.

Example 2 Preparation of Washcoat Compositions Comprising Second SCRCatalyst Method of Making Fresh 3 wt % Cu/Zeolites (Examples 2A and 2B)

Commercially available SAPO-34 (CHA) (Example 2A) and SSZ-13 (CHA)(Example 2B) were NH₄ ⁻ ion exchanged in a solution of NH₄NO₂, thenfiltered. The resulting materials were added to an aqueous solution ofCu(NO₂)₂ with stirring. The slurry was filtered, then washed and dried.The procedure can be repeated to achieve a desired metal loading. Thefinal product was calcined.

Example 2C Method of Making WO_(x)/CeO₂—ZrO₂

A catalyst comprising 15 wt % tungsten supported on a ceria-zireoniamixed oxide comprising 50:50 weight % of ceria and zirconia was preparedby an incipient wetness impregnation method comprising dissolvingsufficient ammonium metatungstate to give the desired 15 wt % W loadingsin deionised H₂O. The total volume of solution was equivalent to thepore volume of the support sample (incipient wetness technique). Thesolution was added to the mixed oxide support material and the resultantmixture was dried overnight at 105° C. and then calcined at 700° C. for3 hours.

Example 3 Preparation of Extruded Honeycomb Catalysts

Extruded active carriers of Example 1 were coated with a washcoatcomprising the second SCR catalyst of Example 2 using the methoddisclosed in WO 99/47260, i.e. comprising the steps of (a) locating acontainment means on top of a extruded active carrier support, (b)dosing a pre-determined quantity of a liquid component into saidcontainment means, either in the order (a) then (b) or (b) then (a), and(c) by applying pressure or vacuum, drawing said liquid component intoat least a portion of the extruded active carrier support, and retainingsubstantially all of said quantity within the extruded active carriersupport. The coated extruded active carriers were then dried in air at100° C. for 1 hour and calcined at 500° C. for 2 hours.

The following combinations of extruded active carrier and washcoat wereprepared.

TABLE 1 Extruded Catalyst Washcoat Extruded Honeycomb Carrier ExampleExample Washcoat Catalyst Example No. Component Component Loading(g/in³) 3A 1B 2C 3.1 3B 1C 2C 3.1 3C 1C 2A 1.8 3D1 1A 2B 1.5 3D2 1A 2B0.5 3E1 1B 2B 0.5 3E2 1B 2B 1.5

Example 5 Synthetic Catalytic Activity Tests

A 2.54 cm×14 cm core was cut from each of the extruded honeycombcatalysts of Example 3 and the catalysts were tested at steady state atthe following temperature points; 180° C., 215° C., 250° C., 300° C.,400° C. and 500° C. in a synthetic catalytic activity test laboratoryapparatus using the following synthetic gas mixture: O₂ 9.3%; H₂O 7.0%;NO_(x) 100 ppm (NO only); NH₃ 100 ppm; Balance N₂ (Swept Volume: 60.000litres/hr).

The results including comparative data are shown in FIGS. 1 to 4.

FIG. 1 shows the results for Examples 3A and 3B compared with anidentical washcoat composition (i.e. Example 2C) coated on an inertcordierite honeycomb carrier at 400 cpsi at 3.4 g/in³ loading; and theextruded catalyst carriers of Examples 1B and 1C per se. As can be seenfrom the results, Examples 3A and 3B show increased NO_(x) conversionperformance across the full temperature range.

FIG. 2 shows the results for Example 3C compared with an identicalwashcoat composition (i.e. Example 2 A) coated on an inert cordieritehoneycomb carrier at 400 cpsi at 1.8 g/in³ loading; and the extrudedcatalyst carrier of Example 1C per se. As can be seen from the results,there is a positive effect in the 200-500° C. temperature range tested.

FIG. 3 shows the results for Examples 3D1 and 3D2 compared withidentical washcoat compositions (i.e. Example 2B) coated on an inertcordierite honeycomb carrier at 400 cpsi at 1.5 g/in³ and 0.5 g/in³loadings; and the extruded catalyst carrier of Example 1A per se. As canbe seen from the results, Examples 3D1 and 3D2 show increased NO_(x)conversion performance at <300° C. and >400° C.,

FIG. 4 shows the results for Examples 3E1 and 3E2 compared withidentical washcoat compositions (i.e. Example 2B) coated on an inertcordierite honeycomb carrier at 400 cpsi at 1.5 g/in³ and 0.5 g/in³loadings; and the extruded catalyst carrier of Example 1B per se. As canbe seen from the results, Examples 3E1 and 3E2 show increased NO_(x)conversion performance at >400° C.

For the avoidance of any doubt the entire contents of all documentscited herein are incorporated herein by reference in their entirety.

1. Extruded honeycomb catalyst for nitrogen oxide reduction according tothe selective catalytic reduction (SCR) method in exhaust gases frommotor vehicles, comprising an extruded catalyst carrier in honeycombform comprising a first SCR catalytically active component and with aplurality of channels through which the exhaust gas flows duringoperation, and a washcoat coating comprising a second SCR catalyticallyactive component, the washcoat coating being in the form of a layerapplied to the extruded catalyst carrier, wherein the first SCRcatalytically active component and the second SCR catalytically activecomponent are each independently selected from the group consisting of:(i) vanadium catalyst with vanadium as catalytically active component;(ii) mixed-oxide catalyst with one or more oxides, in particular thoseof transition metals or lanthanides as catalytically active component;and (iii) a metal zeolite catalyst comprising an Fe or a Cu zeolite aCu-CHA catalyst.
 2. Honeycomb catalyst according to claim 1, wherein inthe extruded catalyst carrier the vanadium catalyst has, as active maincomponents, vanadium oxide, titanium oxide, tungsten oxide in aproportion by volume of 10 to 85%.
 3. Honeycomb catalyst according toclaim 1, wherein the proportion of active components in the extrudedcarrier is reduced by comparison with a conventional uncoated extrudedhoneycomb catalyst and lies in particular in the range between 10 and 60vol. %.
 4. Honeycomb catalyst according to claim 29, wherein the neutralcomponent is selected from the group consisting of a clay, aluminumoxide, and kaolin.
 5. Honeycomb catalyst according to claim 29, whereina proportion of the neutral component lies in the range of 10 to 70 vol.%.
 6. Honeycomb catalyst according to claim 1, wherein the washcoatcoating, at least in a frontal area of the carrier—in relation to adirection of flow of the exhaust gas during operation—is free from noblemetals.
 7. Honeycomb catalyst according to claim 1, wherein the carrierhas a rear area—in relation to a direction of flow of the exhaust gasduring operation—on which there is a noble metal coating to preventammonia slip.
 8. Honeycomb catalyst according to claim 7, wherein thewashcoat coating extends over the entire length of the carrier and alsocovers the noble metal coating in the rear area of the carrier. 9.Honeycomb catalyst according to claim 1, wherein the washcoat coatingand the carrier have a BET surface area in the range of about 40-80m²/g.
 10. Honeycomb catalyst according to claim 1, wherein the layerthickness of the washcoat coating lies in the range of 30 to 100 μm. 11.Honeycomb catalyst according to claim 1, wherein the honeycomb form haswebs and the web width is 150 to 220 μm.
 12. Honeycomb catalystaccording to claim 1, wherein the extruded catalyst carrier is a mixedoxide catalyst and the washcoat coating is a Cu-CHA catalyst. 13.Honeycomb catalyst according to claim 1, wherein the extruded catalystcarrier is a mixed oxide catalyst and the washcoat coating is a vanadiumcatalyst.
 14. Honeycomb catalyst according to claim 1, wherein at leastone of the extruded catalyst carrier and the washcoat coating is aCu-CHA catalyst.
 15. Honeycomb catalyst according to claim 1, whereinthe extruded catalyst carrier is a Cu-CHA catalyst.
 16. Honeycombcatalyst according to claim 1, wherein the extruded catalyst carrier isa Cu-CHA catalyst and the washcoat coating is a vanadium catalyst. 17.Honeycomb catalyst according to claim 1, wherein the extruded catalystcarrier and the washcoat coating are formed from a Cu-CHA catalyst. 18.(canceled)
 19. Honeycomb catalyst according to claim 1, wherein theextruded catalyst carrier and the washcoat coating are formed from avanadium catalyst.
 20. Honeycomb catalyst according to claim 1, whereinthe extruded catalyst carrier and the washcoat coating are formed fromthe same mixed-oxide with one or more of cerium oxide, zirconium oxide,and tungsten oxide as catalytically active component.
 21. Honeycombcatalyst according to claim 1, wherein the carrier is a vanadiumcatalyst and the washcoat coating is a Cu-CHA catalyst.
 22. A set ofvariously different extruded honeycomb catalysts according to claim 1,wherein all the honeycomb catalysts in the set have an identicalcarrier.
 23. Method for producing honeycomb catalysts according to claim1, wherein identically carriers are provided and coated with differentwashcoats.
 24. An exhaust system for a vehicular lean burn internalcombustion engine comprising an extruded honeycomb catalyst according toclaim 1 disposed in a flow conduit thereof.
 25. An exhaust systemaccording to claim 24, comprising means for injecting a nitrogenousreductant or a precursor thereof into the exhaust gas upstream of theextruded honeycomb catalyst.
 26. A lean burn internal combustion enginecomprising an exhaust system according to claim 24 comprising a catalystfor generating NH₃ in situ in exhaust gas upstream of the extrudedhoneycomb catalyst and control means for changing an exhaust gascomposition to a composition which promotes in situ NH₃ on the catalystfor generating NH₃ in situ.
 27. A lean burn internal combustion engineaccording to claim 26, wherein the catalyst for generating NH₃ in situin exhaust gas upstream of the extruded honeycomb catalyst is a dieseloxidation catalyst or a NOx absorber catalyst.
 28. A vehicle comprisingan exhaust system according to claim
 24. 29. The honeycomb catalystaccording to claim 1, wherein the extruded catalyst carrier comprises aneutral component.
 30. The honeycomb catalyst according to claim 1,wherein the vanadium catalyst contains as main components vanadiumoxide, titanium oxide, and tungsten oxide.
 31. The honeycomb catalystaccording to claim 1, wherein the metal zeolite catalyst contains aCu-CHA catalyst in a proportion by volume of 10 to 70%.
 32. Thehoneycomb catalyst according to claim 1, wherein the extruded catalystcarrier further comprises at least one of a binder, a filler and a glassfiber.